This menu provides functions to create, edit and modify the addendum, etc. The functions provided in the ADDENDUM menu are illustrated in Figure 6.3.13.
Figure 6.3.13 Create and Edit Addendum
The following three options allow the user to control the update and display of the addendum and profile.
AUTO UPDATE ADDENDUM (toggle)
If checkbox of this option is toggled on, the addendum is automatically updated after the profile is modified.
ADDENDUM MESH (toggle)
If checkbox of this option is toggled on, the addendum mesh is displayed.
PROFILE (toggle)
If checkbox of this option is toggled on, the profiles are displayed.
NOTE: Pointing to the addendum and double clicking the left mouse button, the program will automatically display the serial number corresponding to each addendum region in the middle of this region. This function enables the user to recognize the serial number conveniently to perform operations such as modify and delete on the corresponding addendum region.
eta/DYNAFORM provides two methods to create the addendum. If checkbox of the BY SEGMENTS option is toggled on, the user can create the addendum by multiple segments using different master profiles. If the checkbox is toggled off, the entire addendum will be created based on a single master profile.
After selecting a master profile, the user clicks on the ASSIGN button to display the dialog box as illustrated in Figure 6.3.14.
Figure 6.3.14 Insert Addendum dialog box
Select one of the types, OUTER, INNER or CORNER addendum, and click on the APPLY button to insert the addendum.
NOTE: If there are multiple binders, the program will prompt the user to specify binder to be added addendum after clicking Apply.
OUTER ADDENDUM (toggle on OUTER)
If checkbox of the BY SEGMENTS is toggled on, the SELECT REGION button is enabled. Click on the button to highlight the outer boundary of the part. The following message is printed in the message prompt window:
SELECT A NODE ON PART BOUNDARY AS STARTING POINT
After selecting a node on the part boundary, the following message is printed in the message prompt window:
SELECT A NODE ON PART BOUNDARY AS END POINT
After two nodes are selected on the outer boundary, click on the APPLY button to create an addendum segment in the defined region. Figure 6.3.15 illustrates a typical addendum segment.
If checkbox of the BY SEGMENT is toggled off, the SELECT REGION button is disabled. The user clicks on the APPLY button to create addendum around the entire outer boundary. Figure 6.3.16 illustrates a typical addendum around the entire out boundary of a part.
Figure 6.3.15 Create Addendum by Segment
Figure 6.3.16 Complete Addendum by Master Profile
INNER ADDENDUM (toggle on INNER)
The SELECT REGION button is enabled if the INNER option is toggled on.
If checkbox of the BY SEGMENTS is toggled on, the user clicks on the SELECT REGION button to select two nodes on the same inner boundary. The user clicks on the APPLY button to generate addendum segment in the selected region.
If checkbox of the BY SEGMENTS is toggled off, the user clicks on the SELECT REGION button to select a node on an inner boundary.
CORNER ADDENDUM (toggle on CORNER)
This function is used to create addendum connecting a part with a flange and the neighboring addenda. In this case, the flange may be part of the binder. Refer to Figure 6.3.19 for illustration of a typical part with flange on the binder.
The steps listed below are used to create a corner addendum:
1. Select CORNER and ADVANCED, as shown in Figure 6.3.17. ADVANCED is used to create the PO line for corner addendum. The user can use the Create Spline Line function in ADVANCED options to create a PO line, as shown in Figure 6.3.20. About detailed descriptions for all the functions in ADVANCED, please refer to Section 5.2.11 , Split Surface.
2. Click the SELECT PROFILE button to select a profile on the addendum boundary. The selected profile will be highlighted as illustrated in Figure 6.3.21.
3. Select two nodes on the part boundary as illustrated in Figure 6.3.22. Click on the YES button to accept the defined corner region.
4. As illustrated in Figure 6.3.17, APPLY button is enabled. Clicking on APPLY, the program will pop up a question dialog box for the user to determine whether boundary line should be selected as the PO line for corner addendum, as shown in Figure 6.3.18. Click YES to select the previously created PO line. The program will auto generate the corner addendum, as shown in Figure 6.3.23.
Figure 6.3.17 Corner Addendum
Figure 6.3.18 Dynaform Question dialog box
Figure 6.3.19 Flange on Binder Surface
Figure 6.3.20 Created PO Line
Figure 6.3.21 Select End Profile on Addendum
Figure 6.3.22 Select Two Nodes on Part Boundary
Figure 6.3.23 Generated Corner Addendum
Once MODIFY button is selected, the program will pop up the MODIFY ADDENDUM dialog box, as shown in Figure 6.3.24.
Figure 6.3.24 Modify Addendum
The user can modify addendum by the following 6 methods.
1. SMOOTH
This option allows the user to modify addendum by selecting POP Line, Bar Height, Bar Height, Bar Width, CBar Height or Wall Angle.
Once the SMOOTH option is selected, all the section lines and POP lines on addendum are displayed in graphic window. As illustrated in Figure 6.3.25, the purple line is the section line and the black line is the POP line. Then select a smooth type and select a PROFILE. The entire addendum where located the selected profile will be the object for this smooth operation.
Figure 6.3.25 Profile and POP Line
POP Line
This function allows the user to change the addendum by smoothing the shape of part POP line. after a profile is selected, the program will highlight the POP line in the selected region as shown Figure 6.3.25 and pop up a dialog box as shown in Figure 6.3.26.
Figure 6.3.26 Smooth POP line
There are three methods can be used to smooth the POP line.
AUTO SMOOTH
Automatically smooth the POP LINE in the selected region.
MANUAL SMOOTH
Entire POP LINE is smoothed according to the movement of slider. The SELECT FIXED POINTS option enables the user to select more than one fixed point. These selected points will not be moved during the smooth operation.
THROUGH FIXED POINTS
This function allows the user to smooth a segment of the POP LINE by selecting a number of fixed points on the POP LINE. Click on the PREVIEW button to view the smoothed POP LINE. If the smoothed shape is acceptable, clicks on the APPLY to accept the smoothed POP LINE. Click OK to exit the SMOOTH dialog box. Click on the CLOSE button in the SMOOTH ADDENDUM dialog box to exit the menu. The profiles and the addendum are automatically updated according to the smoothed POP LINE.
Figure 6.3.28 illustrates the smoothed POP line and the relevant profiles. After the POP line is smoothed, click CLOSE to exit the dialog box. The program will update the profiles and addendum according to the smoothed POP line. The updated addendum is illustrated in Figure 6.3.29.
Figure 6.3.27 Selected POP Line for Smoothing
Figure 6.3.28 Smoothed POP Line and Profiles Through Fixed Points
Figure 6.3.29 The Updated addendum
BAR HEIGHT
This function allows the user to smooth drawbar height of the profiles in the selected region. The program prompts the user to select a segment of profile to define the region. The operation is similar to the POP LINE smoothing.
BAR WIDTH
This function allows the user to smooth drawbar width of the profiles in the selected region. The program prompts the user to select a segment of profile to define the region. The operation is similar to the BAR HEIGHT.
CBAR HEIGHT
This function allows the user to smooth CBar height of the profiles in the selected region. The program prompts the user to select a segment of profile to define the region. The operation is similar to the POP LINE smoothing.
WALL ANGLE
This function allows the user to smooth wall angle of the profiles in the selected region. The program prompts the user to select a segment of profile to define the region. The operation is similar to the POP LINE smoothing.
2. MORPH
This function enables the user to modify addendum by morphing the POP LINE, BAR HEIGHT, BAR WIDTH, CBAR HEIGHT and WALL ANGLE. Once this option is selected, the user needs to select a morph type and click on the APPLY button. The program prompts the user to select the starting and ending profile to define the region to be modified.
POP LINE
This function allows the user to morph selected region of the POP LINE. The user needs to select the starting and ending profile to define the region that is subjected to morphing. If more than one region is defined in the addendum, the starting and ending profiles in each region are highlighted with a circle at each profile. After selecting two profiles, the user needs to confirm the selection in order to highlight the POP LINE as illustrated Figure 6.3.30. The morphing operation of POP LINE is similar to the LINE MORPHING function. Figure 6.3.311 illustrates the morphed POP LINE and the related profiles. After the POP LINE is morphed, the user can click on the CLOSE button to dismiss the dialog box. The profiles and addendum are updated according to the morphed POP LINE. Figure 6.3.32 illustrated the updated addendum after the POP LINE is morphed.
Figure 6.3.30 Selected POP Line for Morphing
Figure 6.3.31 Morphed POP Line and Profiles
Figure 6.3.32 Updated Addendum According to the Morphed POP Line
BAR HEIGHT
This function allows the user to morph drawbar height of the profiles in the user-defined region. The user selects the starting and ending profile to define the region. The operation is similar to the POP LINE morphing operation, with an exception that the control line on top of the drawbar is morphed to alter the drawbar height of the profiles.
BAR WIDTH
This function allows the user to morph the drawbar width of the profiles in the user-defined region. The user selects the starting and ending profiles to define the region. This operation is similar to the BAR HEIGHT line morphing operation with an exception that the control line on top of the drawbar is morphed to alter the drawbar width of the profiles.
CBAR HEIGHT
This function allows the user to morph the counter bar height of the profiles in the user-defined region. The user selects the starting and ending profiles to define the region. This operation is similar to the POP LINE morphing operation with an exception that the control line on the bottom of the counter bar is morphed to alter the counter bar height of the profiles.
WALL ANGLE
This function allows the user to morph the wall angle of the profiles in the user-defined region. The user selects the starting and ending profiles to define the region. This operation is similar to the POP LINE morphing operation with an exception that the POP LINE is morphed to alter the wall angle of the profiles.
3. MERGE
This function enables the user to merge the control line of the POP LINE, BAR HEIGHT, BAR WIDTH, CBAR HEIGHT and WALL ANGLE to a selected line. The profiles are repositioned according to the distance from the control line to the selected line. Once this option is selected, the Create Spline button will be activated, as shown in Figure 6.3.33. Clicking on this button, the program will pop up the Create Spline dialog box as shown in Figure 6.3.34 . Refer to Section 6.1.4.1 INNER FILL for detailed description of this dialog box.
Figure 6.3.33 Merge Addendum Figure 6.3.34 Create Spline
POP LINE
Modify profiles according to the merged POP LINE.
BAR HEIGHT
Modify profiles according to the merged BAR HEIGHT control line.
BAR WIDTH
Modify profiles according to the merged BAR WIDTH control line.
CBAR HEIGHT
Modify profiles according to the merged CBAR HEIGHT control line.
WALL ANGLE
Modify profiles according to the merged WALL ANGLE control line.
Figure 6.3.35(a) illustrates the definition of a straight line for MERGE POP LINE operation. Figure 6.3.35(b) illustrates the result of the profiles after the POP LINE is merged to the selected line. The addendum mesh is automatically updated after the MERGE ADDENDUM dialog box is closed.
(a) Merge POP Line (b) Merge POP Line Result
Figure 6.3.35 Merge
4. EDIT FLINE
This function enables the user to modify addendum by editing the entire POP LINE, BAR HEIGHT, BAR WIDTH, CBAR HEIGHT and WALL ANGLE. Once this option is selected, the user needs to select an edit type and click on the APPLY button. The program pops up a dialog box as illustrated in Figure 6.3.36. In this dialog box, click ADD POINT button to add control points on the boundary line and then click on the middle mouse button to confirm; click REMOVE POINT button to remove the control points on the boundary line; click MOVE POINT button to move the control points on the boundary line and then click on the middle mouse button to confirm. After editing the boundary line, click EXIT button to update the addendum automatically.
Figure 6.3.36 Edit FLine
ADD POINT
Click this button to add control point on the boundary line. Click the middle mouse button to confirm after adding, or click the left button to add control point on boundary line.
REMOVE POINT
Click this button to remove control point from the boundary line, or click the right mouse button to remove the control point from the boundary line.
MOVE POINT
Click this button to move the control point on the boundary line. Click the middle mouse button to confirm after moving or hold the left mouse button move the control point on the boundary line.
Clicking EXIT button after editing the boundary line, the program will automatically update the addendum.
5. SPLIT
This function enables the user to divide an addendum segment into two independent segments. This function is useful for locally modifying the addendum without changing the shape of other addenda. Once this option is selected, the options POP LINE, BAR HEIGHT, BAR WIDTH, CBAR HEIGHT and WALL ANGLE will be disabled. The user should select a profile in the region to be split. If the addendum region where the profile locates is closed, the program will prompt the user to select another profile to split this closed region. If the selected region is open, the program will automatically split this region along the profile.
After splitting, a new addendum name is listed in the addendum list, while a master profile type is listed in the master profiles list.
6. COMBINE
This option allows the user to combine two adjacent independent regions into one region. Once this option is selected, the options POP LINE, BAR HEIGHT, BAR WIDTH, CBAR HEIGHT and WALL ANGLE will be disable, the program will prompt the user to select two adjacent independent addendum regions. After the selection, the program will automatically combine the two regions into one region.
This function enables the user to remove the selected addendum from database. The user selects an addendum from the ADDENDUM LIST and clicks on the DELETE button as illustrated in Figure 6.3.13. eta/DYNAFORM highlights the selected addendum and displays a dialog box.
Click on the YES button to confirm removal of the selected addendum. If NO is selected, the operation is aborted.
Once the user clicks on the COPY button, the program will pop up a dialog box as shown in Figure 6.3.37. With this dialog box, the user can COPY, MIRROR, MOVE, or PATCH the addendum.
Figure 6.3.37 Copy Addendum dialog box
l COPY
This function enables the user to copy a region of addendum to another position. If there is more than one addendum region in the database, the program prompts the user to select a profile region:
PICK A PROFILE regeon
The user can select a profile in the addendum region to be copied. The entire addendum corresponding to this PROFILE will be highlighted, as shown in Figure 6.3.38(a). The program will prompt the user to select a target node on part boundary as starting point for the addendum to be copied:
PICK NODE ON DIE BOUNDARY AS DESTINATION POSITION
(a) (b)
Figure 6.3.38 Copy Addendum
After a destination position is selected on the part boundary, the program pops up a Dynaform Question dialog box for the user to confirm the copied position and highlight the new part boundary, as shown in Figure Figure 6.3.38(b). If the position of new boundary is not correct, select NO to put the new boundary on the other side of the reference point. Click YES to accept the boundary location. The selected addendum will be copied as shown in Figure 6.3.39.
Figure 6.3.39 Copy Addendum Result
l MIRROR
This function generates the entire addendum by mirroring it about a symmetry plane. The user must define the symmetry axis for the part in the DFE/PREPARATION menu in order to use this function. Refer to Section 6.1.2 for description about the symmetry definition.
The symmetry axis is displayed after the mirror function is selected. The user selects an addendum segment to display the mirrored boundary. From the displayed DYNAFORM QUESTION dialog box as illustrated in Figure 6.3.40(a), the user selects YES to mirror the addendum. The mirrored result is illustrated in Figure 6.3.40(b).
(a) (b)
Figure 6.3.40 Mirror Addendum
NOTE: If the generated addendum by the MOVE, COPY or MIRROR function interferes with existing addendum, the operation will be aborted.
l MOVE
This function enables the user to move a selected addendum segment to another location. If more than one addendum segment are available in the database, the following message is given in message prompt window:
PICK A PROFILE GROUP
After the user selected a group of profile, eta/DYNAFORM highlights the profiles and addendum of the selected group as illustrated in Figure 6.3.41(a). The following message is then given in the message prompt window.
PICK NODE ON DIE BOUNDARY AS DESTINATION POSITION
(a) (b)
Figure 6.3.41 Move Addendum
A DYNAFORM QUESTION dialog box is displayed requesting the user to confirm the selected location. The new boundary on the part is highlighted, as illustrated in Figure 6.3.41(b). If the location of the new boundary is wrong, the user can select NO to put the new boundary on the opposite side of the reference point. Click on the YES button to accept the boundary location. The selected addendum will be moved to the location as illustrated in Figure 6.3.42.
Figure 6.3.42 Move Addendum Result
l PATCH
This function is used to fill an addendum segment between two adjacent addenda. The filled segment is typically a transition area between two adjacent addenda generated using different profile types. Figure 6.3.43 illustrates a typical addendum region of different profile types.
Figure 6.3.43 Transition Area between Adjacent Regions
The user need to select two end profiles of adjacent addenda after clicking on the PATCH button. After the profiles are selected, the segment is created. Figure 6.3.44 illustrates a typical transition area generated by the patch function.
Figure 6.3.44 Typical Result of Patch Function
This function is used to estimate the elongation ratio of the blank along the specified profile direction. It is useful for estimating the level of blank deformation.
If this function is selected, the user needs to select a profile. After selecting a profile, two section lines are highlighted as illustrated in Figure 6.3.45. These section lines are created from the plane of the profile intersecting with the binder and the die.
Figure 6.3.45 Select profile
Figure 6.3.46 Point Selection on Line
Next, the user selects a reference point on the highlighted line or clicks the middle button to select the default point. As illustrated in Figure 6.3.46, the lines are divided into three lines identified as 1, 2, 3 respectively. The result is printed in the message prompt window:
ELONGATION: 23%; LENGTH: 1: 434.1 2:521.7 3:207.7
ELONGATION is the elongation percentage of the specified section line after deformation. It is calculated by the following equation:
ELONGATION = (LENGTH 1+ LENGTH 3 -LENGTH 2)/ LENGTH2 *100%
LENGTH 1 and LENGTH 3 indicate the lengths of the punch and addendum after deformation, respectively. LENGTH 2 indicates the length of the line 2 prior to deformation.
Then, the user continues by selecting another profile or click on the right mouse button to exit the function.
If the AUTO UPDATE ADDENDUM option is not selected, eta/DYNAFORM will not update the addendum after the profiles are modified. This function allows the user to update the addendum mesh according to the modified profiles. If the AUTO UPDATE ADDENDUM option is selected, this function is not necessary.